Weatherable coating for stained composite thermoset or thermoplastic surface plastic building products

ABSTRACT

A stain/topcoat system for non-porous thermoset and/or thermoplastic articles comprises a pigmented stain having substantially only a single binder resin which promotes adherence of a topcoat, and a topcoat which is an aqueous dispersion of a film forming polymer and a curable organopolysiloxane microemulsion. The topcoat displays exceptional adhesion and weatherability to pigmented stained surfaces.

This is a divisional of application Ser. No. 09/313,792 filed on May 18,1999 now U.S. Pat. No. 6,120,852, which is a division of Ser. No.08/912,443, filed Aug. 18, 1997 now U.S. Pat. No. 5,948,849.

FIELD OF THE INVENTION

The present invention pertains to weatherable coating systems suitablefor application to thermoset or thermoplastic composite surfaces havingminimal surface porosity. More particularly, the present inventionpertains to a stain, a topcoat, and to a stain and topcoat system whichcan be easily applied by the consumer to produce an aesthetic,weatherable surface, particularly on exterior doors and door entrycomponents.

BACKGROUND OF THE INVENTION

Conventional finishing methods for exterior doors and door systemcomponents, where a traditional finely finished wood grain appearance isdesired, have involved staining a bare wood surface with dye and/orpigment-bearing stains followed by application of one or more coats ofexterior varnish. A seal coat is sometimes applied prior to the stainand topcoat to seal the pores of the wood and to promote a more adherentand uniform stain and topcoat. The stain is virtually always solventborne, as water based stains have the effect of raising the grain, thusrequiring an intermediate sanding step which is labor and timeintensive. In addition to the solvent contained in the stain, stainscontain drying oils as carriers, for example heat-bodied linseed oil.Generally, several different oils are provided to promote penetration ofthe stain into the wood surface.

After the stain has dried, one or more transparent topcoats are applied.Traditional topcoats are varnishes containing dissolved resins such ascopal, often in conjunction with a drying oil. More recently, chemicallymodified natural resins and synthetic polymers have replaced all or partof natural resins, especially for outdoor use. In addition, to providesuperior weatherability, ultraviolet absorbers have been added. Despitethe advances made in such finishes, varnishes still generally requirelight sanding or abrading with steel wool or the like between coats, ornecessitate the addition of the second coat prior to the full drying ofthe previous coat. Otherwise, delamination between varnish coats mayoccur. Sanding and similar treatments are time consuming, and judgingthe proper time to apply a second coat onto a not fully-cured prior coatrequires some skill and experience. Despite these drawbacks,stain/varnish systems continue to be used on exterior door systems.

Recently, high quality exterior door systems employing molded thermosetand/or thermoplastic composite skins have become commercially available.These door systems are compression molded to exhibit a wood grainappearance, and when properly finished, are difficult to distinguishfrom natural wood doors. These composite doors offer several advantagesover natural wood products, such as freedom from warpage, lower cost,greater insulation efficiency, and the like. Unfortunately, thestain/varnish systems in use for finishing natural wood doors are onlymarginally acceptable for composite doors. A satisfactory finish mayoften be achieved under production conditions where skilled workers,sophisticated spray equipment, drying ovens and the like are available.However, such systems are ill-suited for application by the consumer.

The difference between the ease with which finishes may be applied tonatural wood products on the one hand and composite exterior doorsystems on the other, is due to the nature of the materials involved.Natural wood is a porous and absorbent product. Hence, dyes maypenetrate the wood fibers as well as into the wood pores. The latter mayalso serve to trap and retain pigment, as may partially abraded fibersgenerated in sanding the wood prior to finishing. However, compositedoor skins are constructed of sheet molding compound (SMC) or otherthermoset or thermoplastic matrices, often containing fillers which mayrange from wood flour to finely ground minerals and/or glass fibers.Despite the presence of fillers, the composite door skins areessentially non-porous. Thus, stains containing dyes as the colorant arelargely ineffectual, and pigmented stains require a higher amount ofpigment than would be required for a conventional wood stain. The lackof porosity and the generally smooth surface of such products requirethe stain pigments to be physically adhered to the surface.

Furthermore, the drying oils used in conventional stains, particularlythose of lower viscosity, act as subsurface emollients in wood, butremain as an exterior thin film on composite skins. Lower molecularweight oils, being unable to penetrate the essentially non-poroussurface, may remain tacky or require lengthy drying times or oven cure.During weathering due to light exposure, these oils experience scissionof naturally occurring unsaturated molecular sites. The scissionproduces a variety of lower molecular weight, liquid and often volatilecomponents, which causes the subsequently applied topcoat to blister,coming off in sheets.

The detrimental effects of drying oil vehicles may be minimized bysubstituting quickly evaporating solvents such as mineral spirits,naphtha, or the like. However, such stains tend to dry rapidly, leavingapplication marks, i.e., “brush marks” where overlapping coats of stainare applied. Elimination of drying oil components results in littleadherence of pigment to the surface. This minimal adherence may beacceptable in porous products, but is highly problematic when non-poroussurfaces are involved.

Adkins, et al., in U.S. Pat. No. 4,923,760, discloses water-borneemulsions employing two different maleinized linseed oils together withcosolvents such as propylene gylcol tertiary butyl ether and a varietyof hydrocarbons. However, such stains are still formulated for porouswood surfaces and are not well suited to non-porous composite doorskins. Lowering the amount of the oil vehicles would be appropriate, butthe stains then dry too fast and have only a limited capacity to stablydisperse pigment.

Pigmented stains, whether solvent-borne or water borne, aretraditionally protected by aromatic polyurethane topcoats. When thepreviously deposited stain contains low levels of scissionable dryingoils, failure by blistering and peeling is substantially minimized.However, aromatic polyurethanes are subject to severe degradation bylight. Exposure to sunlight causes degradation which ultimately resultsin ablative loss of the coating when applied to non-porous surfaces.Polyurethane varnishes often contain sacrificial ultraviolet (UV)protectants. However, the ultraviolet light protection package istypically consumed in as few as eight months exposure to sunlight. Asthe stain coat is not strongly adhered to non-porous substrates, failureof the topcoat results in ablative loss of the stain layer, typically inless than two months after the topcoat is breached.

Aqueous topcoats have been used with some success, as indicated by thedisclosures of U.S. patents to Gobel et al. (U.S. Pat. No. 5,342,882)and Sanders et al. (U.S. Pat. No. 4,509,981). Water-based topcoatsemploying aliphatic urethane-acrylic latexes are commercially available.The use of a non-sacrificial UV protectant package in these coatingcompositions provides a substantial increase in durability of underlyingresin-bound solid pigmented coating relative to the degree of protectionprovided by aromatic polyurethane finishes. However, these finishes areincompatible with pigmented stains having little or no resin binder andhigh pigment loading. This incompatibility is believed due to therelative differences between the somewhat hydrophilic pigment particlesand the hydrophobic topcoat.

It would be desirable to provide a pigmented stain suitable for use onrelatively non-porous thermoset and thermoplastic composite surfaces,particularly door skins. It would be further desirable to provide suchpigmented stains in a formulation which can easily be applied by theconsumer in a uniform manner, without resort to the use of expensive andnot readily available production equipment. It would be yet furtherdesirable to provide a topcoat which is compatible with the pigmentedstain, and which exhibits a high, continuing degree of ultravioletprotection and weathering resistance. The stain/topcoat system shouldnot employ two-component coatings with limited pot life, and should beremovable by traditional paint strippers should the need arise.

SUMMARY OF THE INVENTION

The present invention pertains to a pigmented stain containing a uniqueresin binder, which is highly effective to stain thermoset and/orthermoplastic, essentially non-porous surfaces; and to an aqueous,transparent topcoat which is compatible therewith. The stain/topcoatsystem provides a finish system which is suitable for consumerapplication, which can be removed by conventional paint strippers, andwhich, following application, presents a highly aesthetic, weatherablesurface.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The pigmented stain of the present invention contains a high loading ofpigments necessary to impart the degree of coloration required fornon-porous thermoset and/or thermoplastic composite materials,particularly door skins, trim, etc., and a specific resin binder, in asolvent system which preferably employs a tail vehicle in addition toconventional fast drying solvents. The resin binder is adicyclopentadiene-modified drying oil as disclosed by U.S. Pat. No.5,288,805, herein incorporated by reference, and commercially availableas DILULIN™ copolymer resins from Cargill, Inc. It has been surprisinglyfound that one copolymer resin is adequate not only to provide therequisite adhesion of pigment to substrate, but also, in conjunctionwith the formulation of the topcoat, to allow for the use of largeamounts of pigment in the stain without compatibility problems. Thus, itis preferred that the dicyclopentadiene-modified drying oils constitutethe largest part, and preferably all or substantially all of the resinbinder.

The dicyclopentadiene-modified drying oil is preferably prepared byreacting dicyclopentadiene in an amount of from about 10 weight percentto about 40 weight percent with a drying oil or mixture of drying oilshaving relatively high iodine numbers, preferably above 150, and morepreferably in the range of 170 to 195. Linseed oil is the preferreddrying oil, however other oils such as tung oil, dehydrated castor oil,and other oils may be used as well, or in admixture with linseed oil.The dicyclopentadiene is added to the drying oil in small increments atrelatively high temperature, i.e., 250-270° C. with stirring. It isbelieved that the dicyclopentadiene is converted to cyclopentadienewhich then reacts with the unsaturated sites of the drying oils in aDiels-Alder reaction. The preparation of such modified oils and theiruse with oil-modified polyurethanes in polyurethane varnish is disclosedin U.S. Pat. No. 5,288,805.

The dicyclopentadiene-modified linseed oil is present in the stain in anamount of from about 20 weight percent to about 45 weight percent, morepreferably 30 to 40 weight percent, and most preferably about 32 to 38weight percent. The pigment loading is from about 15 weight percent toabout 35 weight percent, more preferably 20 weight percent to about 30weight percent, and most preferably about 25 to 30 weight percent.Solvents are present in amounts of about 20 weight percent to 40 weightpercent, more preferably 25 to 35 weight percent, and most preferablyabout 30-35 weight percent. Of the total solvents, approximately 10weight percent to about 30 weight percent, preferably 15 weight percentto about 25 weight percent are slowly evaporating solvents commonlyknown as “tail solvents.” The remainder of the solvents exhibit fast tomoderate evaporation, such as mineral spirits, naphtha, solvent 142petroleum distillate, and the like. It is preferred to use combinationsof these faster evaporating solvents such that the solvents flash off atdifferent intervals. The majority of solvent, i.e., >50%, should flashoff within a period of from 2 to 10 minutes. Most preferably, solvent142 petroleum distillate, mineral spirits, and tridecyl alcohol tailsolvent are employed in a weight ratio of about 10:10:5, with the weightratio of dicyclopentadiene-modified linseed oil to tail solvent beingapproximately 3:1.

In addition to pigments, dicyclopentadiene-modified linseed oil, andsolvents, the stain may contain other known additives, for example,leveling agents; drying agents, i.e., metal naphthenates such as cobaltnaphthenate, calcium naphthenate, and magnesium naphthenate; ultravioletabsorbers, preferably of the non-sacrificial type, i.e., hindered aminestabilizers such as TINUVIN® 292 and TINUVIN® 328; wax; thickeners suchas various clay minerals; and the like. The stain is preferably free ofordinary drying oils such as unmodified or bodied linseed oil, tung oil,and the like; and is preferably also free of other secondary resins suchas urethane resins and oil-modified alkyd polymers.

The preparation of the stain is not overly critical, and may beperformed by conventional paint preparation techniques. For example, thepigments, in standard commercial grade, are added to a first portion ofthe dicyclopentadiene-modified linseed oil and well blended in a mixingtank, three roll mill, Cowles mixer, etc. Sand milling or ball millingmay also be used. In some cases, pigment size reduction is desired inaddition to full wetting of the pigment-surface. A surfactant such asBYK™ 156 may aid in dispersing and wetting the pigment with the resinbinder. Following wetting of the pigment and any desired size reduction,the resulting mill base is diluted with solvent, additional resin added,and various driers, leveling agents, thickeners, and the like are added.Blending of the mixture is continued until a uniform dispersion isobtained.

The stain may be applied to the non-porous thermoset and/orthermoplastic composite by conventional means, i.e., by brushing,spraying, sponging, rolling, wiping, and the like. In general, excessstain is removed by wiping with a clean lint free rag or the like, butpreferably by means of a china bristle brush. The stain is generallyapplied at temperatures between 5° C. and 45° C., and should be allowedto dry for approximately 48 hours at room temperature under dryconditions. Drying time may be adjusted depending upon the temperatureand humidity. After the stain is dry, the topcoat may be applied.

The topcoat exhibits unexpectedly excellent compatibility with theinventive stain layer, particularly so in view of the fact that thetopcoat is an aqueous composition. The topcoat comprises a non-siloxane,film-forming polymer latex, preferably an acrylic latex; an aliphatic oraromatic polyurethane latex, most preferably an aliphatic polyurethanelatex; an acrylic vinyl latex; an acrylic polyurethane latex; an acrylicpolyester latex; mixtures of the above, and the like. Most preferablyFLEXTHANE® urethane-modified acrylate resins available from Air Productsare used. The pH of the aqueous latexes must be suitable for thedispersed phase, and is preferably between 8 and 11, adjusted byaddition of suitable acid or alkaline additives, particularly withammonium hydroxide. FLEXTHANE® 620 is particularly preferred as the filmforming polymer.

The term “latex” as used herein pertains to an emulsion, microemulsion,or dispersion of the respective polymer as a discontinuous phase inwater as a continuous phase. The particle size is not overly critical,and may vary, for example, from smaller than 0.001 μm to 2 μm or larger,preferably from 0.01 μm to 0.5 μm. The dispersed phase will preferablyremain stably dispersed in the continuous phase. If the dispersed phasesettles or separates, it should be readily redispersible by means ofsimple agitation, as by stirring or the use of a paint mixer or thelike. Latexes with small particle sizes are preferred. By the term“dispersible” as it applies to the non-siloxane, film-forming polymer,is meant that the polymer may be dispersed or emulsified in water toform a latex as that term is used herein.

The topcoat composition may contain conventional additives such ascosolvents, leveling agents, flatting agents, emulsifiers and emulsionstabilizers, biocides, thickeners, suspending agents, and in particular,ultraviolet protection additives. Examples of suitable cosolventsinclude the various glycol ethers and acetates available from the DowChemical Company under the tradename DOWANOL® glycol ethers andacetates. Aliphatic alcohol cosolvents such as methanol, ethanol,n-propanol, 2-propanol, n-butanol, 2-ethylhexanol, tridecyl alcohol, andthe like may be used, as can also ketones such as methylethylketone,2-pentanone, cyclohexanone; and aliphatic and aliphatic hydrocarbons.The latter may be used in quantities such that stable emulsions may bemaintained.

The key to the compatibility and weatherability of the topcoat, however,is due to the presence of an organopolysiloxane microemulsion,preferably one containing one or more curable or crosslinkableorganopolysiloxanes. The presence of this microemulsion is believed toalter the hydrophobicity of the topcoat, rendering the latter compatiblewith the stain formulation of the present invention.Alkoxyalkyl-functional organopolysiloxanes such as Wacker Silicones 43Aorganopolysiloxane are suitable, for example. Although siloxanemicroemulsions are preferred for use herein, stable emulsions containinglarger particle sizes are useful as well.

The organopolysiloxanes are curable organopolysiloxanes which arereadily available. Such curable organopolysiloxanes have reactivefunctional groups such as alkoxy, silanol, chloro, hydrido, acetoxy, andthe like. The functional groups may be terminal groups or may bedistributed along the polysiloxane chain. Preferably, the averagefunctionality of the organopolysiloxanes is greater than two such that acrosslinked thermoset polymer is obtained upon cure. However, lowerfunctionality organopolysiloxanes are also suitable, so long as theimproved topcoat weatherability is maintained. Suitableorganopolysiloxanes are identified in U.S. Pat. No. 4,913,972, which isherein incorporated by reference. A preferred organopolysiloxane isWacker 43A organopolysiloxane, available from Wacker Silicones, Adrian,Mich. organopolysiloxanes which contain unsaturated organic groups suchas allyl-, vinyl-, vinylether, and other unsaturation-functional groupsare also useful. These organopolysiloxanes may further crosslink underthe influence of light exposure.

The term “curable” includes resins which are crosslinkable as well. Theterm “curable” is intended to reflect a curing reaction which creates ahigher molecular weight cured polymer as compared to the molecularweight of the uncured organopolysiloxane. By the term “molecular weight”is meant number average molecular weight.

In addition to the curable organopolysiloxane, the topcoat may containother organopolysiloxanes which promote water beading. Theseorganopolysiloxanes may be curable, may be essentially inert, or mayinteract with other system components such as the film-forming polymereither by chemical reaction or polar or ionic attraction. Examples ofwater beading agents are trimethylsiloxy end-cappedpolydimethysiloxanes, α,ω-dihydroxypolydimethylsiloxanes, and inparticular, amino-functional organopolysiloxanes, for exampleα,ω-[3-aminopropyl]polydimethylsiloxanes. A preferred beading agent isWacker Silicones BS 1306 organopolysiloxane.

The topcoat preferably contains in weight percent from about 35 to 60percent water, preferably 40-55 percent water, and more preferably about45-55 percent water; from about 25 to about 55 percent film formingpolymer, preferably from about 35 to about 50 percent, and morepreferably about 35 to about 45 percent; from about 2 to about 25percent organopolysiloxane, preferably from about 3 to 10 percent, andmore preferably from about 3 to about 8 percent; and sufficientsurfactant to provide a stable dispersion, preferably about 1 to about 8percent, preferably about 1 to about 5 percent, and most preferablyabout 2 to about 4 percent. The surfactants may be anionic, cationic,amphoteric, or non-ionic. Mixtures of various surfactants may be used.The type of surfactant should be tailored to the type of polymer latex.For example, anionic polymer latexes may be adversely affected by theuse of large quantities of cationic surfactants, as coagulation mayoccur. The selection of suitable surfactants is within the skill of theart once the general formulation is known.

In addition to the above ingredients, the topcoat preferably contains anultraviolet protection package. This package may contain one or moreultraviolet absorbers, preferably of the non-sacrificial type. Finelydivided inorganic particles in the nanosize range, particularly thosewhich are colorless (white) may be used as an ultraviolet absorber.Examples are titanium dioxide, silica, and various ceramic materials.The fine particle size is generally provided by flame pyrolysis or spraypyrolysis. Such UV absorbing particles may be used in amounts up toabout 5 percent by weight, preferably from about 0.1 weight percent toabout 2 weight percent, and more preferably about 0.2 weight percent toabout 1 weight percent.

In addition to finely divided inorganic particle UV absorbers, solubleor dispersible organic absorbers such as hindered amines, cinnamic acidesters, and the like may be used, generally in amounts up to about 5weight percent, more preferably 0.1 to about 3 weight percent, and mostpreferably from about 0.5 to about 2 weight percent. Preferred UVabsorbers are the various TINUVIN absorbers available from Ciba Geigy.

Without wishing to be bound to any particular theory, the inventivetopcoat of the subject invention is believed to comprise aninterpenetrating polymer network. Thus, it is believed that thepolyurethane polymer and polysiloxane polymer cure in such a fashionthat the polymers form a complex network which assists in producing aweatherable coating. This conclusion is based in part on thedrying/curing behavior whereby the topcoat clears as it dries,indicating little phase separation; and also upon the fact that ifsiloxane is added too rapidly during topcoat preparation, soft balls ofgelatinous polymer may form. It is generally known in the wood finishingarts that polysiloxanes should be avoided during finishing operations toavoid surface defects such as “orange peel” and “cats eyes.” The factthat relatively large amounts of polysiloxane remain compatible with thefilm forming polymer may be due to the formation of an interpenetratingnetwork which than effectively prevents phase separation.

Interpenetrating polymer networks have been disclosed asantithrombogenic polymers in U.S. Pat. Nos. 4,872,867 and 4,6616,064.However, the IPNs of the former are prepared in strong aprotic solvents,while the IPNs of the latter were prepared in the melt. Neither of thesetechniques can be used for transparent topcoats. Further solvent-borneIPNs prepared from urethane modified acrylates and both siliconized andnon-siliconized epoxy resins are presented in “Cure Behavior ofSilicone-Epoxies and Urethane Modified Acrylates in InterpenetratingNetworks”, J. COATINGS TECH. Vol. 68, No. 854, March 1996, pp 65-72.

The stain/topcoat system of the present invention displays excellentweatherability, as measured by ASTM G53-88 accelerated weathering test.Moreover, the topcoat itself, even when used over conventional oil-basedstains, also displays excellent weatherability. The weatherabilityshould exceed 1500 hours minimally by the above test, should preferablyexceed 2000 hours, more preferably 2500 hours, and most preferablyexceeds 3000 hours.

The preparation of the aqueous topcoat may be performed in numerousways. However, the addition of the polysiloxane compound must beaccomplished in such a manner so as to prepare a stable microemulsion.Simply adding the entire amount of siloxane at one time is generallyineffectual. It has been found advantageous to prepare a mill basecontaining the film forming polymer and other non-siloxane additives andutilize water or a portion of the mill base to form a polysiloxane“preblend.” The preblend is then added to the remaining portion of themill base in slow continuous or incremental additions with modestagitation such that the total addition takes place over a period of 25minutes to 10 hours, preferably 40 minutes to 6 hours. When incrementaladdition is utilized, it has been found advantageous to add up to about8 percent by weight of the preblend, more preferably 0.5 to 2.5 weightpercent of the preblend at each increment, the increments spacedapproximately 1-5 minutes apart, more preferably a minimum of 2 minutes,and most preferably 3 minutes apart. Thus, with 2.5 weight percentincrements spaced 3 minutes apart, the entire addition of preblend tomill base will take approximately 2 hours. The preblend preferablyconsists of 20-80 weight percent polysiloxane and 80-20 weight percentwater and/or mill base, more preferably 30-65% polysiloxane, and mostpreferably about 40-60% polysiloxane, the remainder preferably beingmill base and/or water. The preblends advantageously contain WackerSilicone 43A alkoxyalkyl polysiloxane or other alkoxy-functionalpolysiloxane in an amount of from 50 to 100% based on totalpolysiloxane, and 0-50% of an aminoalkyl-functional polysiloxane,preferably 0-20%, and most preferably 5-15% based on total polysiloxane.Other polysiloxanes may be used as well, for example, unsaturatedphotocurable or heat-curable polysiloxanes.

The topcoat is preferably applied as two layers with a total drythickness of 10-100 μm, preferably 13-75 μm, and more preferably 30-60μm. The topcoat is preferably applied at ambient temperatures in the 5°C. to 45° C. range, with three hours between coats. While the topcoat ispreferably applied over a pigmented stain on a non-porous thermosetand/or thermoplastic surface, the inventive topcoat may be applied toother surfaces devoid of stain, and to porous surfaces, stained orunstained, as well.

Having generally described this invention, a further understanding canbe obtained by reference to certain specific examples which are providedherein for purposes of illustration only and are not intended to belimiting unless otherwise specified.

EXAMPLE 1

A preferred walnut stain formulation is prepared as follows:

A mill base is prepared in a suitable container employing a high shearmixer with a high speed dispersant blade such as a Cowles blade. Toapproximately 85 kg of dicyclopentadiene-linseed oil copolymer, such asDILULIN™ copolymer, are added pigments such as 100 kg of burnt umber, 5kg of red 40, and 15 kg of bone black; surfactants such as 1.8 kg ofBYK™ 156 ammonium Polyacrylate dispersant; and thickeners such asCLAYTONE™ modified montmorillonite thickener, the quantity of which isdetermined by the consistency desired.

After 30 minutes of blending to thoroughly wet out the pigments and toreduce the pigment size to be small enough to fit into the texture ofthe thermoplastic or thermoset composite surface, the mill base isdiluted to volume and adjuvants blended in under high shear mixing.These include 70 kg of dicyclopentadiene-linseed oil copolymer; hinderedamine light stabilizers, such as 5 kg of TINUVIN™ 292 and 10 kg ofTINUVIN™ 328; 1.6 kg of anti-mar wax; co-solvents, such as 65 kg ofsolvent 142, 30 kg of tridecyl alcohol, and 50 kg of mineral spirits;drying agents, such as 5 kg of 10% calcium napthenate, 3 kg of zirconiumnaphthenate, and 1 kg of magnesium naphthenate; and leveling agents,such as 0.5 kg of SKINO™ methylethylketoxime anti-skinning agent.

EXAMPLE 2

A preferred topcoat formulation is prepared as follows:

A mill base is prepared in a small container in a high shear mixer byadditions of 100-1000 g, preferably 725 g, ultrafine titanium dioxide,in approximately 8 L of clean water. The mixture is sheared forapproximately 30 minutes at approximately 2000 rpm using a high speeddispersand blade such as a Cowles blade. To this is added fatting agentsuch as LOVEL™ 27 silica flatting agent, the quantity of which isdependent on the finish desired: flat, satin, semi-gloss, or glossy.Other adjuvants include rheological aids, such as modified syntheticclays for consistency, preferably 800 g of LAPONITE™ clay; surfactantssuch as 1675 g of BYK™ 024 defoamer, a mixture of organopolysiloxanes,and/or 425 g of BYK™ 181 anionic/non-ionic wetting aid defoamerconsisting of alkanolammonium salts of polyfunctional polymer; andanti-marring waxes such as SHAMROCK™ S-381 wax, the amount of which isdetermined by the product performance requirements, preferably 650 g.

The mill base is transferred to a larger tank and the remainingnon-polysiloxane materials are blended in under high shear conditions.Approximate additions are as follows: 160 kg of urethane-acrylic hybridpolymer resin; surfactants such as 1.1 kg of BYK™ 321 polyether-modifiedpolydimethylsiloxane copolymer and 1.8 kg of BYK™ 346 polyether-modifiedpolydimethylsiloxane surfactant; hindered amine stabilized ultravioletlight stabilizers such as 725 g of Tinuvin™ 292; anti-fungal andanti-microbial adjuvants such as 650 g of POLYPHASE™ P-20-T3-into-2-propynylbutyl carbonate antimicrobial and 380 g of PROXEL™ GXL;anitmicrobial as well as 1.8 kg co-solvent such as tridecyl alcohol.

A 20 L hydrophobicity-modifying polysiloxane preblend is prepared at50-1000 rpm, using a Cowles blade, in a high shear mixer. The maximumagitation speed is determined by the shear sensitivity of the particularorganopolysiloxane resins, while the minimum speed is determined byeconomics of manufacture. About 10 L of the main topcoat mixturedescribed above is withdrawn, or as an alternative, water may be used toprepare the preblend. Solvents such as those used in topcoat preparationmay not be used as they fail to mix without detrimental dispersiontexture. Over a minimum period of about 20 minutes, continuous orincremental additions of main topcoat mixture or water are added to thehydrophobicity modifying preblend containing such as 9.6 kg oforganopolysiloxane, for example, Wacker Silicone 43A. Adjuvantwater-beading agents such as 1 kg of amino-functional organosiloxane,for example Wacker Silicones 1306 organopolysiloxane, are added as partof the preblend.

The organopolysiloxane-containing hydrophobicity modifying preblend isadded to the main topcoat mixture in continuous or incremental additionsat a rate of about 1-160 mL, preferably 50 mL; or up to 8 volume % ofthe preblend, preferably 0.5-2.5 volume % of the preblend; spaced aminimum of 2, preferably 3 minutes apart.

EXAMPLES 3-5 AND COMPARATIVE C1

The products of Examples 1 and 2 are compared to commercial stain andsolvent based polyurethane topcoat by exposing finished door skins madefrom wood grain molded SMC. The tests were conducted with UV B313 bulbsand a test cycle of 4 hours of exposure to UV light at 60° C. followedby 4 hour exposure to condensation at 50° C., in accordance with theQUV™ Accelerated Weathering test following ASTM G53-88.

TABLE 1 HOURS TO EXAMPLE STAIN TOPCOAT FAILURE C1 Zar ™ mineral Zar ™Exterior 800 spirits based Polyurethane wood stain 3 Example 1 stainZar ™ Exterior 1000 Polyurethane 4 Zar ™ mineral Example 2 3000 spiritsbased topcoat wood stain 5 Example 1 stain Example 2 3400 topcoat

Example C1 is a comparative example employing high quality commercialwood stain and exterior polyurethane solvent-borne topcoat. The finishsystem of Comparative Example C1 failed in 800 hours. By substitutingthe inventive stain for the commercial stain, the weatherability isextended to 1000 hours in Example 3, a 25% increase, while utilizing thesame commercial topcoat. By changing the topcoat to the inventivetopcoat, the weatherability of the finish system of Example 4, againemploying the commercial stain, is extended dramatically to 3000 hours,an increase of 275% over the system of C1. A further increase to 3400hours weatherability is obtained by utilizing both the inventive stainand topcoat in Example 5.

EXAMPLES 5 AND 6. COMPARATIVE EXAMPLES C2 AND C3

Two SMC wood grained skins were stained with high quality commercialstain and the stain of Example 1. Portions of these stained skins weretopcoated with the topcoat of Example 2 and a similarly prepared topcoatformulation but devoid of organopolysiloxane. The stains were subjectedto the cross-hatch adhesion test of ASTM D3359. The results arepresented in Table 2. The polysiloxane-free topcoat is designated as“siloxane free.”

EXAMPLE STAIN TOPCOAT ADHESION 6 Zar ™ mineral Example 2 5B spiritsbased wood stain 7 Example 1 stain Example 2 5B C2 Zar ™ mineralSiloxane Free 1B spirits based wood stain C3 Example 1 stain SiloxaneFree 0B

The results indicate that the subject topcoat is far superior to asimilar topcoat formulation containing no polysiloxane.

EXAMPLE 7 AND COMPARATIVE EXAMPLE C4

Test door skins prepared from a variety of substrates were subjected toweatherability tests in Florida and Arizona. The test panels included apolyurethane substrate, a panel molded from sheet molding compound, anda CLASSIC CRAFT™ door skin. A total of six different pairs ofsubstrates, most being glass fiber-reinforced, were used. One of eachpair was stained with the stain of Example 1 and the topcoat of Example2. This set of six panels constitute Example 7. The second of each pairof panels was stained with a mineral spirit-based oil stain followed bya high quality commercial topcoat, ZAR™ Exterior Polyurethane. This setof panels constitutes Comparative Example C4. Samples were exposedoutdoors for a period of six months. The color change (Delta E) wasmeasured in accordance with ASTM D2244-93, “Method for Calculation ofColor Differences From Instrumentally Measured Color Coordinates.” GlossChange was measured in accordance with ASTM D523-89 “Standard Method forSpecular Gloss.” Color changes and gloss changes were averaged for eachset of panels. The results are presented below.

TABLE 3 COLOR PANEL SET CHANGE¹ GLOSS CHANGE Example 7 4.17 8.12Comparative 15.01 18.89 Example C4 ¹Average from six different panels.

Of the panels tested, the CLASSIC CRAFT™ panel and the panel preparedfrom sheet molding compound were the best performers overall with theinventive stain/topcoat system.

By the term “weatherability” is meant performance of stain, topcoat, orstain/topcoat systems in exterior exposure, for example corresponding tothe ASTM G53-88 test. By the terms “major” or “majority” is meant 50% ormore. By the term “minor” it is meant less than 50%. By “non-porous” ismeant the porosity of a thermoset and/or thermoplastic articlecontaining not more than a minor quantity of organic and/or inorganicfillers. By the term “transparent” is meant a product or film preparedtherefrom which is transparent to the naked eye or slightly translucentsuch that newsprint may be easily read through 1 mm thickness. The term“consisting essentially of” when applied pertaining to stain resincontent means that the resin contains only most minor amounts of resinother than dicyclopentadiene-modified drying oils, i.e., not more thanabout 10% by weight based on the total amount of resin. The resin binderpreferably contains a majority of dicylopentadiene-modified drying oil,more preferably in excess of 70 weight percent, more preferably greaterthan 80 weight percent, and yet more preferably greater than 90 weightpercent. Most preferably, this modified drying oil is the sole binderresin. By the term “thermoset and/or thermoplastic” is meant a thermosetpolymer, a thermoplastic polymer, or a mixture of thermoset andthermoplastic polymers. These polymers, which may be collectively termed“plastics” may contain fillers, adjuvants, etc., as previouslydisclosed.

What is claimed is:
 1. A finished weatherable door, comprising: a) adoor having a first face and a second face, at least one of said facescomprising a thermoset and/or thermoplastic skin; b) a pigmented staincoating on at least one of said faces comprising a thermoset and/orthermoplastic skin; c) a dried transparent topcoat, said topcoat, priorto drying, being an aqueous topcoat comprising i) from about 25 weightpercent to about 55 weight percent based on the weight of the aqueoustopcoat of at least one non-polysiloxane film forming polymer, at leastone of said film forming polymers being dispersible in water; ii) atleast one curable organopolysiloxane in the form of an emulsion, saidcurable organopolysiloxane present in an amount of from about 2 to 25weight percent based on the weight of said aqueous topcoat; and iii)water superficial to said pigmented stain coating.
 2. A finished,weatherable door, comprising: a) a door having a first face and a secondface, at least one of said faces comprising a thermoset and/orthermoplastic skin; b) at least one skin having thereon a dried,pigmented stain comprising, prior to drying: 1) from about 15% to about35% of one or more pigments; 2) from about 20% to about 45% of a resinbinder comprising dicyclopentadiene-modified drying oil; 3) from about20% to about 40% of at least one volatile solvent; c) a transparenttopcoat superficial to said pigmented stain.
 3. A finished, weatherabledoor, comprising: a door having at least one face comprised of athermoset and/or thermoplastic skin, said skin surface finished with astain/topcoat system comprising a dried stain superficial to which is adried topcoat, said stain comprising, in percent by weight based on thetotal weight of said pigmented stain and prior to drying: 1) from about15% to about 35% of one or more pigments; 2) from about 20% to about 45%of a resin binder comprising dicyclopentadiene-modified drying oil; 3)from about 20% to about 40% of at least one volatile solvent, saidtopcoat comprising a dried aqueous topcoat comprising, prior to drying,4) from about 25 weight percent to about 55 weight percent solids basedon the weight of the aqueous topcoat of one or more non-siloxanefilm-forming polymers, at least one of said non-siloxane film-formingpolymers dispersible in water; 5) an emulsion of one or more curableorganopolysiloxanes; and 6) water wherein said finished surface exhibitsweatherability as measured by ASTM G53-88 of greater than 2000 hours. 4.The finished weatherable door of claim 1 wherein said non-polysiloxanefilm forming polymer, prior to drying, is present in a amount of 35 to45 weight percent in said aqueous topcoat.
 5. The finished weatherabledoor of claim 1, wherein said organopolysiloxane prior to drying, ispresent in an amount of 3 to 10 weight percent in said aqueous topcoat.6. The finished weatherable door of claim 1, wherein saidnon-polysiloxane film forming polymer comprises one or more polymersselected from the group consisting of acrylic latex, aliphaticpolyurethane latex, aromatic polyurethane latex, acrylic vinyl latex,acrylic polyurethane latex, and acrylic polyester latex.
 7. The finishedweatherable door of claim 4, wherein said non-polysiloxane film formingpolymer comprises one or more polymers selected from the groupconsisting of acrylic latex, aliphatic polyurethane latex, aromaticpolyurethane latex, acrylic vinyl latex, acrylic polyurethane latex, andacrylic polyester latex.
 8. The finished weatherable door of claim 5,wherein said non-polysiloxane film forming polymer comprises one or morepolymers selected from the group consisting of acrylic latex, aliphaticpolyurethane latex, aromatic polyurethane latex, acrylic vinyl latex,acrylic polyurethane latex, and acrylic polyester latex.
 9. The finishedweatherable door of claim 1, wherein said organopolysiloxane is acurable organopolysiloxane containing one or more types of reactivefunctional groups selected from the group consisting of alkoxy, silanol,chloro, hydrido, acetoxy, allyl, vinyl, and vinylether.
 10. The finishedweatherable door of claim 4, wherein said organopolysiloxane is acurable organopolysiloxane containing one or more types of reactivefunctional groups selected from the group consisting of alkoxy, silanol,chloro, hydrido, acetoxy, allyl, vinyl, and vinylether.
 11. The finishedweatherable door of claim 6, wherein said organopolysiloxane is acurable organopolysiloxane containing one or more types of reactivefunctional groups selected from the group consisting of alkoxy, silanol,chloro, hydrido, acetoxy, allyl, vinyl, and vinylether.
 12. The finishedweatherable door of claim 3 wherein said non-polysiloxane film formingpolymer, prior to drying is present in a amount of 35 to 45 weightpercent in said aqueous topcoat.
 13. The finished weatherable door ofclaim 3, wherein said organopolysiloxane, prior to drying, is present inan amount 3 to 10 weight percent in said aqueous topcoat.
 14. Thefinished weatherable door of claim 3, wherein said non-polysiloxane filmforming polymer comprises one or more polymers selected from the groupconsisting of acrylic latex, aliphatic polyurethane latex, aromaticpolyurethane latex, acrylic vinyl latex, acrylic polyurethane latex, andacrylic polyester latex.
 15. The finished weatherable door of claim 3,wherein said organopolysiloxane is a curable organopolysiloxanecontaining one or more types of reactive functional groups selected fromthe group consisting of alkoxy, silanol, chloro, hydrido, acetoxy,allyl, vinyl, and vinylether.